Shale-gas separating and cleanout system

ABSTRACT

This invention relates to the separation of shale, gas and fluid at a shale-gas well. The shale debris and water from a shale-gas well is tangentially communicated to a vessel where the cyclonic effect within the vessel facilitates the separation of the gas from the shale debris. The separated shale debris and fluid falls to a jet assembly whereby it encounters a jet communicating a fluid therethrough. A venturi provides a motive force to the shale debris and fluid sufficient to propel it into a collection bin. The shale-gas separator incorporates a fluid bypass overflow line to prevent a buildup of fluid within the vessel. The shale-gas separator also incorporates an internal aerated cushion system (IACS) pipe for further motivating the shale debris and into the jet assembly, to ensure the walls of the vessel are clean, and to provide an air cushion restricting gas migration to the jet assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/049,726, filed Oct. 9, 2013, which is a continuation of InternationalApplication No. PCT/US2011/032122, filed Apr. 12, 2011, the entiredisclosures of which are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

During the drilling phase of well exploration, it is common to hitpockets of gas and water. When using an air drilling process in a shaleformation, shale cuttings, dust, gas and fluid/water create a volatilemixture of hard-to-handle debris; especially when encounteringpreviously fractured formations. Drilling operations and debris disposalaccount for the majority of the volatility and fire risk during thedrilling process. Without limitations, these operations include fluidrecovery, gas irrigations and debris disposal.

As the number of wells drilled in a given area increase, the possibilityof encountering a fractured formation within an active drillingoperation, increases. This possibility presents the drilling operatorwith a problem of removing shale cuttings, along with dust, fluid/waterand gas. There is no effective way to separate the shale cuttings, mutethe dust, by-pass the fluid/water encountered, and control/burn thewaste gas in the air portion of the drilling program.

Air drilling is one method of drilling into shale formations, but itcreates large volumes of dust. Unfortunately, the dust cannot bedischarged into the environment due to the many governmental regulationsrelated to dust control for shale-gas drilling operations. Thus, suchdrilling efforts must overcome this problem or face substantialpenalties and fines.

As gas is often encountered during the air drilling operation from apreviously fractured formation, a combustible gas cloud may be createdand linger near the ground. A similar gas cloud may exist and lingerwithin and/or around the debris disposal pits. These combustible gasclouds create a fire hazard at the drilling site, and downwindtherefrom. Accordingly, many additional governmental regulations forshale-gas drilling relate to the handling and processing of debris fromsuch wells in order to avoid a volatile, combustible gas cloud.

The foregoing issues show there is a need for an apparatus to separatethe shale-gas-water mixture into non-volatile components, and provideenvironmentally safe collection and disposal of the shale debris, fluidand formation gas burned a safe distance from wellbore.

SUMMARY OF THE INVENTION

In one aspect, the following invention provides for a shale-gasseparator. The shale-gas separator comprises a vessel and a jetassembly. The vessel has an intake pipe defined thereon, where theintake pipe is positioned to tangentially communicate a shale-gas-fluidmixture into the vessel. A gas release vent is defined on the vessel,and positioned to communicate gas therefrom. The jet assembly has a sideopening connected to a port positioned on the bottom of the vessel. Thejet assembly has a first end and a second end defined thereon. A jet isconnected to the first end. A jet assembly outlet is secured to thesecond end.

In another aspect, a shale-gas separator and clearing apparatus isprovided. The shale-gas separator and clearing apparatus comprises avessel, a jet assembly and internal aerated cushion system (IACS) pipe.The vessel has an intake pipe defined thereon. The intake pipe providestangential communication of a shale-gas-fluid mixture into the vessel.The vessel has a top and a bottom, where the top and the bottom eachhave a port disposed therethrough. The jet assembly is secured to thebottom. The jet assembly has a jetted input and a venturi output. TheIACS pipe is centrally disposed within the vessel, and extends towardsthe port in the bottom. The IACS pipe has at least one discharge nozzledefined thereon.

In yet another aspect, a shale-gas separator dust eliminator isprovided. The dust eliminator comprises a sidewall, an inlet and anoutlet. There is at least one fluid jet disposed through the sidewall.There is a plurality of baffles positioned within the housing, where afirst baffle is positioned beneath the fluid jet and oriented to deflectfluid towards the outlet. There is a second baffle complementarilypositioned within the housing between the fluid jet and the outlet,wherein the baffles are positioned to interrupt the flow of fluidthrough the housing.

Numerous objects and advantages of the invention will become apparent asthe following detailed description of the preferred embodiments is readin conjunction with the drawings, which illustrate such embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a simplified schematic elevational view of a wellsite influid communication with a shale-gas separator.

FIG. 2 depicts a simplified schematic plan view of a wellsite in fluidcommunication with a shale-gas separator.

FIG. 3 depicts a lower left perspective view of a shale-gas separator.

FIG. 4 depicts right side elevational view of a shale-gas separator.

FIG. 5 depicts a left side elevational view of a shale-gas separator.

FIG. 6 depicts a front elevational view of a shale-gas separator.

FIG. 7 depicts a rear side elevational view of a shale-gas separator.

FIG. 8 is plan view of a shale-gas separator.

FIG. 9 is a sectional detail view taken from FIG. 4 along line 9-9, andillustrates a debris shield.

FIG. 10 is a sectional detail view taken from FIG. 4 along line 10-10,and illustrates an intake pipe having a tangential input and a wearplate.

FIG. 11 is sectional view taken from FIG. 6, long line 11-11, andillustrates an internal aerated cushion system (IACS) pipe.

FIG. 12 depicts a side view of a jet assembly.

FIG. 13A depicts a side view of a dust eliminator having spiralingbaffles.

FIG. 13B is a sectional view taken from FIG. 13A along line 13B-13B, andillustrates one of the spiraling baffles.

FIG. 13C is a sectional view taken from FIG. 13A along line 13C-13C, andillustrates another of the spiraling baffles.

FIG. 13D is an elevational end view of a dust eliminator havingspiraling baffles.

FIG. 14A is a bottom view schematic of slotted outlet muffler with theslot on one side.

FIG. 14B is a bottom view schematic of an outlet muffler having holes onone side.

FIG. 15A is a side view schematic of a slotted outlet muffler disposedwithin a housing.

FIG. 15B is a sectional view of a slotted outlet muffler disposed withina housing taken from FIG. 15A along lines 15B-1B.

FIG. 15C depicts a perspective view of an alternative configuration ofthe collection bin, slotted outlet muffler without a housing and fluidoverflow bypass line.

FIG. 16 depicts a perspective view of a jet assembly and pressurizedfluid input lines, and optional valve.

FIG. 17 depicts a detail view of the vessel and fluid overflow bypassline.

DETAILED DESCRIPTION

Referring to FIGS. 1-3, the inventive shale-gas separator is illustratedand generally designated by the numeral 10. As shown by the drawings andunderstood by those skilled in the art, shale-gas separator 10 andcomponents thereof are designed to be associated with a well 12. Asdiscussed herein, shale-gas separator 10 is associated with well 12,shale formations 14 and drilling strategies. The drilling strategiesinclude air drilling in shale formations. However, the invention isapplicable to multiple drilling techniques with cuttings, dust, debris,gas and fluid from wells 12 other than those associated with shaleformations 14.

Shale-gas separator 10 is in air/fluid communication with well 12. FIGS.1 and 2 illustrate shale debris, dust, gas and fluid being communicatedto shale-gas separator 10 in pipe 16. The fluid is typically water,mist, foam, detergent or aerated mud. Shale-gas separator 10 receivesthe shale-gas-fluid mixture at intake pipe 18. Intake pipe 18 is securedto and protrudes through wall 20 of vessel 22. Optional dust eliminator24 is illustrated as being directly connected to intake pipe 18.However, dust eliminator 24 may also be positioned in-line with pipe 16.

Shale-gas separator 10, illustrated in FIGS. 1-7 illustrates vessel 22in fluid communication with intake pipe 18. As illustrated in FIG. 3,intake pipe 18 flows into tangential input 26 through the sidewall 20 ofvessel 22 and opens within vessel 22, thereby defining the tangentialflow and initiating the cyclonic effect with vessel 22.

Vessel 22 is generally circumferential with domed top 28 and conicalbottom 30. Domed top 28 has a port disposed therethrough. The port indomed top 28 functions as gas release vent 32, which is in fluidcommunication with flare stack feedline 34 and is capable ofcommunicating gas from vessel 22 to a flare (not shown) placedsufficiently far enough from the well to mitigate any threat ofaccidental ignition of gas, Although not shown, gas release vent 32optionally includes one-way valves, splash-guards, and/or back-flowpreventers placed in flare stack feedline 34 prior to igniting theflare. Conical bottom 30 has port 36 disposed therethrough. Port 36 isin fluid communication with jet assembly 38.

Interiorly disposed between tangential input 26 and gas release vent 32is debris shield 40. Debris shield 40 interiorly extends outward fromwall 20 and covers about 40 percent to about 75 percent of the innerdiameter of vessel 22. As illustrated in FIGS. 4-9, debris shieldextends across the inner diameter of vessel 22 about 4 feet (about 1.2meters). Additionally, FIGS. 4 and 5 illustrate debris shield 40 ashaving downward angle 42 and being oriented towards conical bottom 30.Downward angle 42 is between about −5° and about −60° below the horizon,and is illustrated in FIGS. 4 and 5 as having an angle of about −15°below the horizon. Downward angle 42 provides for the downwarddeflection of shale debris and fluid, while allowing the separated gasto escape towards gas release vent 32. Debris shield 40 has gas vents 44penetrating therethrough along edges 46 to facilitate gas release.

In operation, debris shield 40 receives the shale-gas-fluid mixture fromintake pipe 18, and working in concert with the cyclonic effectcommunicated by intake pipe 18 and tangential input 26, causes the gasto separate from the shale-gas-fluid mixture. The separated gas risestowards gas release vent 32 where it is communicated from vessel 22. Theshale debris and fluid fall towards conical bottom 30, where it isreceived by jet assembly 38.

FIG. 10 illustrates wear plate 48 secured to wall 20 and positioned toreceive shale-gas-fluid mixture from intake pipe 18 and tangential input26. Wear plate 48 may be permanently affixed to wall 20, or it may beremovably affixed. As illustrated, wear plate 48 is interiorly welded towall 20. In the alternative, not shown, wear plate 48 is bolted, orotherwise secured to wall 20. As illustrated, wear plate 48 is betweenabout 18 inches to about 24 inches wide (about 0.46 meters to about 0.61meters) and covers about one-half of the circumferential interior ofwall 20. As illustrated, wear plate 48 is about 0.5 inches (about 1.3centimeters) thick. Wear plate 48 begins where tangential input 26 endswithin vessel 22. The longitudinal centerline (not shown) of wear plate48 is centered on tangential input 26, Preferably, wear plate 48 andtangential input 26 are blended together to prevent any edges for inputflow to impinge upon.

As illustrated in FIGS. 1, 3-8, 12 and 16, jet assembly 38 connects toport 36 of conical bottom 30 at a side opening thereon, also referred toas side receiver 50. Side receiver 50 has a shape facilitating the flowof debris and fluid into jet assembly 38. Side receiver 50 surroundsport 36, thereby providing for unimpeded flow into jet assembly 38. Jetassembly 38 has first end 52 and second end 54. First end 52 has jet 56connected thereto. Referring to FIG. 12, jet 56 extends into jetassembly 38 along a center axis of jet assembly 38, and terminatesbetween side receiver 50 and second end 54, Vacuum gauge 58 isillustrated in FIG. 12 as being positioned on side receiver 50 withinjet assembly 38 to measure the drop in pressure or amount of vacuumpulled in inches or kilopascals. In practice, the amount of vacuumpulled by jet assembly 38 is about −10 inches of mercury to about −15inches of mercury (about −34 kilopascals to about −51 kilopascals).

Jet 56 is capable of receiving fluid, either liquid or air, which inturn provides the motive force to the shale debris and fluid to exitthrough second end 54. Preferably, jet 56 is able to use compressed air,compressed inert gas, pressurized water, pressurized hydraulic fluid, orcombinations thereof. Jet assembly 38 also has pressure gauge 60.Pressure gauge 60 provides feedback on the pressure of air/fluid flowinginto jet assembly 38 through jet 56 and to internal aerated cushionsystem (IACS) pipe 62.

Second end 54 communicates the debris and fluid to outlet muffler 64.FIG. 12 depicts second end 54 as venturi 66. Jet assembly outlet 68,illustrated in FIGS. 4-6, 8, 12 and 16, communicates the debris andfluid from second end 54 to collection bin 70 via discharge line 72. Inan alternative embodiment, venturi 66 is part of jet assembly outlet 68that is secured to second end 54.

Jet assembly outlet 66 is secured to discharge line 72, which is incommunication with outlet muffler 64. As illustrated in FIGS. 2 and 15C,outlet muffler 64 is positioned to discharge shale debris and fluid intocollection bin 70. Outlet muffler 64 has at least one discharge port 74.As illustrated in FIGS. 2, 11A-12C, outlet muffler 64 has one to sixdischarge ports 74, but any number will provide the desired discharge.FIGS. 2, 14A, and 15A-15C illustrate discharge port 74 being a slot.FIG. 14B illustrates three discharge ports 74 as holes. Other shapes andsizes of discharge port 74 are understood to be included. For example,discharge port 74 can be elliptical or square. It is also anticipatedthat discharge line 72 can directly discharge the shale debris and fluidwithout outlet muffler 64,

FIGS. 15A and 15B depict outlet muffler 64 with housing 76 surroundingit and being secured thereto. Housing 76 tapers outwardly from top 78 tobottom 80, as illustrated in FIGS. 2, 3, 15A and 15B. Also illustratedin FIGS. 2, 15A and 15B, is outlet muffler 64 with discharge port 74oriented towards bottom 80, FIG. 15A shows one embodiment of outletmuffler 50 secured to housing 76. Additionally, outlet muffler cap 82 isillustrated as extending externally to wall 84 of housing 76. In thisembodiment, discharge port 74 is a slot extending across a substantialdepth 86 of housing 76.

Outlet muffler cap 82 provides impact baffling for debris dischargingthrough outlet muffler 64. Alternatively, internal baffles (not shown)may be used to divert and slow the debris within outlet muffler 64.Another alternative is to not use outlet muffler 64 and secure housing76 directly to elbow 88. This alternative has internal baffles or wearplates on wall 84.

FIG. 15A illustrates housing 76 with sniffer port 89 thereon. Snifferport 89 provides access for a gas sniffer (not shown) to sample theoutput from outlet muffler 64 for the presence of gas, In this context,the gas sniffer includes the capability to detect one or more of thegaseous chemicals found in well 12. In the absence of housing 76,sniffer port 89 is positioned on outlet muffler 64.

Vessel 22 also includes IACS pipe 62. As illustrated in FIGS. 4-8 and11, IACS pipe 62 is elongated and positioned within vessel 22. IACS pipe62 is centrally positioned within conical bottom 30 of vessel 22, andlocated above port 36. IACS pipe 62 has at least one nozzle 66 definedthereon. IACS pipe 62 is positioned within vessel 22 to providepressurized fluid to remove any debris buildup on wall 20 of conicalbottom 30 down to port 36, In use, IACS pipe 62 provides a fluid cushionto mitigate the buildup of gas in jet assembly 38 and vessel 22.

The non-limiting example in FIG. 11 depicts IACS pipe 62 having three tofive sets of nozzles 90 positioned along longitudinal portion 92 of IACSpipe 62. Additionally, the non-limiting example depicts another threecleanout nozzles 90 secured to IACS pipe end 94, and are downwardlyoriented. By way of another non-limiting example, if longitudinalportion 92 of IACS pipe 62 is about three (3) feet (about 1 meter) inlength, nozzles 90 are spaced along longitudinal portion 92 with spacingof about six (6) inches to about 18 inches (about 0.15 meters to about0.5 meters). The spacing between cleanout nozzles 90 is determined bythe size of vessel 22. As shown in FIG. 11, the spacing between nozzles90 is about twelve (12) inches (about 0.3 meters). There may be aplurality of nozzles 90 circumferentially positioned along longitudinalportion 92 at each spacing. Alternatively, there may be a plurality ofnozzles 90 circumferentially and offsettingly positioned alonglongitudinal portion 92 at operator desired spacing.

Referring to FIGS. 4-8 and 11, IACS pipe 62 is secured to and throughwall 20. Although IACS pipe 62 is illustrated as a single line, it maybe formed out of several pipe sections, IACS pipe 62 is in fluidcommunication with pressurized fluid line 96 with line 98 at t-joint100. Line 98 has valve 102 disposed between pressurized fluid line 96and IACS pipe 62. Valve 102 provides control of the fluid communicatedto IACS pipe 62, and is illustrated as a manually operated valve.However, automating valve 102 is understood to be within the skill ofone knowledgeable of the art.

As illustrated in FIG. 16, pressurized fluid line 96 communicatespressurized fluid to jet 56 and to IACS pipe 62 through line 98. Valve104 is positioned upstream from t-joint 100 and pressure gauge 60, andcontrols the fluid communicated to jet 56. Valve 104 may also bemanually or automatically operated. Although, using the same fluid forboth jet 56 and IACS pipe 62 is preferred, an alternative is to useseparate types of fluid communicated through separate supply lines (notshown). For example, compressed air is communicated to jet assembly 38and pressurized water is communicated to IACS pipe 62. Compressed airwill be the most common fluid communicated through pressurized fluidline 96 and line 98 due to its availability at the wellsite.

FIG. 16 also illustrates pressure gauge 60 and vacuum gauge 58 asdescribed above. Preferably, valve 104 is adjusted to set a minimumvacuum condition in jet assembly 38. One embodiment facilitatesachieving the above-mentioned desired vacuum range of about −10 inchesof mercury to about −15 inches of mercury (about −34 kilopascals toabout −51 kilopascals). In this embodiment, jet 56 operates using fluidhaving a pressure in the range of about 75 pounds per square inch toabout 200 pounds per square inch (about 517 Kilopascals to about 1,379Kilopascals). Valve 104 is adjustable until vacuum gauge 58 indicatesthe vacuum is within desired range.

FIGS. 4-8 illustrate fluid overflow bypass line 106, or overflow line106. Overflow line 106 communicates any excess fluid buildup withinvessel 22 away from vessel 22. As illustrated, intake port 108 isoriented towards conical bottom 30, is centrally positioned withinvessel 22 and below than intake pipe 18. Preferably, intake port 108 isalso positioned above IACS pipe 62.

Overflow line 106 is secured to and through wall 20 at point 110.Preferably, point 110 is below intake pipe 18. Overflow line 106 isconnected to fluid bypass discharge line 112, or bypass line 112. Bypassline 112 discharges to any receptacle capable of receiving the fluid,with one example shown in FIG. 15C. Preferably, bypass line 112discharges to another device (not shown) capable of separating any gasfrom the fluid.

To provide additional access to vessel 22, at least one manway 114 andat least one cleanout/observation hatch 116 are utilized and disposedthrough wall 36. Manway 114 is disposed through wall 20 above conicalbottom 30. Cleanout/observation hatch 116 is disposed through wall 20 ofconical bottom 30. Manway 114 and cleanout/observation hatch 116 aresized to provide complete or partial access to the interior of vessel22. As shown, manway 114 is about 24 inches (about 0.6 meters), andcleanout/observation hatch 116 is about 10 inches (about 0.25 meters).

As illustrated in FIGS. 1-8, 10 and 13A-D dust eliminator 24 has inlet118, outlet 120, fluid jet 122, and a plurality of baffles. Asillustrated, the plurality of baffles include first spiral baffle 124and second spiral baffle 126. Fluid jet 122 is disposed through sidewall128 of dust eliminator 24 near inlet 118. First spiral baffle 124 andsecond spiral baffle 126 are positioned from about inlet 118 to aboutoutlet 120. Second spiral baffle 126 is complementarity positionedwithin dust eliminator relative to first spiral baffle 124. Fluid jet 94is positioned near inlet 118 above first spiral baffle 124 and secondspiral baffle 126. First spiral baffle 124 and second spiral baffle 126deflect the fluid, typically water, being propelled from fluid jet 122towards outlet 120. First spiral baffle 124 and second spiral baffle 126interrupt an axial flow of fluid and debris through the dust eliminator,thereby inducing a spiraling flow of the fluid and debris through dusteliminator 24. This spiraling flow action causes the dust and fluid tomix, thereby reducing dust.

An alternative for first spiral baffle 124 and second spiral baffle 126is to use offsetting baffles (not shown) that are alternating andobliquely positioned. In this case, the first baffle will be obliquelypositioned below fluid jet 122 and capable of deflecting the fluidtowards outlet 120. The subsequent baffles alternate and provide pointsof impact for the fluid and the debris of shale-gas. The fluid impactsinterrupt flow of fluid through the dust eliminator 24. In this setup,there are at least two baffles and preferably three or more baffles.

Referring to FIGS. 1-8, shale-gas separator 10 is shown as being carriedby skid 130. Preferably, skid 130 is transportable across a standardU.S. highway.

In an embodiment illustrating the use of shale-gas separator 10, atypical well 12 using shale-gas separator 10 discharges the shale-gasdebris through pipe 16 to the optional dust eliminator 24, where afluid, such as water, is injected therein and encounters the debris,thereby reducing and/or eliminating any dust. The shale-gas debris maybe shale-gas-fluid debris. Exiting from the optional dust eliminator 24,the debris is communicated to vessel 22 where it is cyclonicallycommunicated therein through intake pipe 18 and tangential input 26.

The debris cyclonically spins around within vessel 22. In a non-limitingexample, vessel 22 has a diameter of about 72 inches (about 1.83meters). In this same non-limiting example, debris shield 40 has15-degree downward angle 42 and covers about 66 percent of the interiorof vessel 22, which is about four (4) feet (about 1.2 meters). Debrisshield 40 restricts and deflects solids and fluid downwardly, away fromgas release vent 32. The released gas is communicated upwardly to gasrelease vent 32, whereby it is further communicated to flare stackfeedline 34 and burned at a flare positioned a safe distance from thewell 12.

The solid debris and fluid fall downwardly into conical bottom 30 andthrough port 36 where the solids and fluid enter jet assembly 38. Jet56, using air or fluid, propels the solids and fluid through jetassembly 38 to venturi 66. As the solids and fluid flow through venturi66, they are propelled to outlet muffler 64. Outlet muffler 64discharges the solids and fluid into collection bin 70.

If jet assembly is blocked or clogged, IACS pipe 62 is positioned toprovide high-pressure fluid that is expelled through cleanout nozzles 90within conical bottom 30. The high-pressure fluid is commonly air due tothe availability at wellsites. The high-pressure fluid creates a cushionor barrier to keep gas from being communicated to jet assembly 38. Theplacement of IACS pipe 62 provides for maximum or additional force ofpressurized fluid to further motivate the solids out of conical bottom30 of vessel 22. Additionally, IACS pipe 62 provides fluid to removedebris build up on the interior of wall 20 of vessel 22. For thisnon-limiting example, the supply of fluid is from the same source offluid provided to jet 56. However, separate sources of fluid for IACSpipe 62 and jet 56 are equally acceptable as is the same source.Additionally, for this non-limiting example IACS pipe 62 is about 2inches (about 5 centimeters) in diameter.

Jet assembly 38 has an additional clean out port, or cleanout plug 131.Clean out plug 131 is illustrated in FIG. 16 as being oppositelypositioned side receiver 50. In the event jet assembly 38 becomes tooclogged to clean it out with pressurized air or fluid, plug 131 can beremoved for manual cleaning.

Referring to FIG. 16, valve 132 is illustrated as being positionedbetween second end 54 and outlet muffler 64. Valve 132 is optional andprovides a means to prevent all flow from vessel 22 through jet assembly38. In this instance, all flow can be forced through overflow line 106.As illustrated in FIG. 16, valve 132 is a knife valve, but any valvecapable of preventing flow will work. In one embodiment, valve 132 isair actuated. As shown in FIGS. 3 and 16, valve 132 is manuallyoperated.

Overflow line 106, functioning as a bypass, provides for a means topassively remove excess fluid, which is typically water, accumulatingwithin vessel 22, As the fluid accumulates, it begins to enter intakeport 108 until it reaches first turn 134. At that time, the fluid beginsto flow out of overflow line 106 and into discharge line 112, where itis deposited into an approved receptacle. As described in thisnon-limiting example, overflow line 106 and discharge line 112 are eachabout 6 inches (about 0.15 meters) in diameter.

Referring to FIGS. 2-8 and 17, external valve 136 is utilized to openand close overflow line 106 to control fluid communication from overflowline 106 to bypass line 112. External valve 136 may be automated, or itmay be manual. The manual system of external valve 136 is illustratedwith handle 138 to open and close it. In the manual mode, an internalindicator float (not shown) and float signal 140, as shown in FIG. 17,are used to notify an operator to open the external valve 136. The samefloat and signal 140 are automatically integrated with an automatedsystem. Signal 140 can be audible, visual, electronic, or a combinationthereof.

FIG. 17 depicts optional vessel pressure gauge 142. Vessel pressuregauge 142 provides the operator with feedback on the current pressurewithin vessel 22.

Other embodiments of the current invention will be apparent to thoseskilled in the art from a consideration of this specification orpractice of the invention disclosed herein. Thus, the foregoingspecification is considered merely exemplary of the current inventionwith the true scope thereof being defined by the following claims.

What is claimed is:
 1. A shale-gas separator, comprising: a vessel intowhich a shale-gas-liquid mixture is adapted to be communicated; a firstport adapted to communicate from the vessel a gas; a second port adaptedto communicate from the vessel a shale debris and fluid separated fromthe shale-gas-liquid mixture; and an overflow line disposed in thevessel to communicate away from the vessel any excess fluid buildupwithin the vessel, the overflow line comprising an intake port; whereinthe vessel comprises a top through which the gas vent is disposed, and aconically-shaped bottom through which the second port is disposed;wherein the intake port of the overflow line is oriented towards theconically-shaped bottom; wherein the shale-gas separator furthercomprises an intake pipe connected to the vessel and via which theshale-gas-liquid mixture is adapted to be communicated into the vessel;wherein the intake port of the overflow line is vertically positionedbetween the second port and the intake pipe; wherein the shale-gasseparator further comprises an internal aerated cushion system (IACS)pipe adapted to provide a fluid cushion within the vessel, the IACS pipebeing centrally disposed within the conically-shaped bottom; and whereinthe IACS pipe is vertically positioned between the second port and theintake port of the overflow line and thus the intake port of theoverflow line is vertically positioned between the IACS pipe and theintake pipe.